CA2400685A1 - Polymer compositions with improved property constancy - Google Patents
Polymer compositions with improved property constancy Download PDFInfo
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- CA2400685A1 CA2400685A1 CA002400685A CA2400685A CA2400685A1 CA 2400685 A1 CA2400685 A1 CA 2400685A1 CA 002400685 A CA002400685 A CA 002400685A CA 2400685 A CA2400685 A CA 2400685A CA 2400685 A1 CA2400685 A1 CA 2400685A1
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- styrene
- acrylonitrile
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L51/00—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers
- C08L51/04—Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bonds; Compositions of derivatives of such polymers grafted on to rubbers
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F279/00—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00
- C08F279/02—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00 on to polymers of conjugated dienes
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08F—MACROMOLECULAR COMPOUNDS OBTAINED BY REACTIONS ONLY INVOLVING CARBON-TO-CARBON UNSATURATED BONDS
- C08F279/00—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00
- C08F279/02—Macromolecular compounds obtained by polymerising monomers on to polymers of monomers having two or more carbon-to-carbon double bonds as defined in group C08F36/00 on to polymers of conjugated dienes
- C08F279/04—Vinyl aromatic monomers and nitriles as the only monomers
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L55/00—Compositions of homopolymers or copolymers, obtained by polymerisation reactions only involving carbon-to-carbon unsaturated bonds, not provided for in groups C08L23/00 - C08L53/00
- C08L55/02—ABS [Acrylonitrile-Butadiene-Styrene] polymers
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- Health & Medical Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Medicinal Chemistry (AREA)
- Polymers & Plastics (AREA)
- Organic Chemistry (AREA)
- Graft Or Block Polymers (AREA)
- Compositions Of Macromolecular Compounds (AREA)
- Manufacture Of Macromolecular Shaped Articles (AREA)
Abstract
The invention relates to polymer compositions of particular graft rubber polymers, during the production of which, rubbers of defined particle size a re obtained by seed polymerisation, using seed latex particles of defined particle size.
Description
Polymer Compositions with Improved Constant Properties ABS moulding compositions or moulding compositions of the ABS type have already been used for many years in large amounts as thermoplastic resins for producing moulded parts of all types. In this connection the property spectrum of these resins can be varied within wide ranges.
Particularly important properties of ABS moulding compositions that may be mentioned include toughness (impact strength, notched impact strength) modulus of elasticity, processability (), Neat resistance, surface gloss, attention being paid to specific prc~perky combinations depending on the area of use.
A particularly important feature for the processing of ABS moulding compositions, particularly when using fully automated production plants, is the constancy of the properties or property combinations of the moulding compositions to be processed.
Although products with relatively narrow tolerance limits can be produced by using modern processes in the ABS production (for example computerised control of polymerisation and compounding), nevertheless for special applications it is necessary to have even more improved constant properties that can be achieved only via the product composition or the product structure.
The object therefore existed of producing thermoplastic moulding compositions of the ABS type that exhibit from batch to batch very constant values for the most important properties also in the case of variations in the individual components that are used. The object according to the invention is achieved by using combinations of special graft rubber polymers in the production of which are employed rubbers with defined particle diameters obtained by seed polymerisation using seed latex particles with defined particle diameters.
The invention provides polymer compositions containing _2_ I) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, styrene and/or acrylonitrile being able to be partially or completely replaced by a-methylstyrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (A) with a mean particle diameter d5o of 230 to 330 nm, preferably 240 to 320 nm, and particularly preferably 250 to 310 nm, II) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, styrene and/or acrylonitrile being able to be completely or partially replaced by a-methyl-styrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (B) with a mean particle diameter d5o of 340 to 480 nm, preferably 350 to 470 nm, and particularly preferably 360 to 460 nm, optionally III) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, wherein styrene and/or acrylonitrile can be wholly or partially replaced by a-methyl styrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (C) and IV) at least one rubber-free copolymer of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, wherein styrene and/or acrylonitrile can be wholly or partially replaced by a-methyl styrene, methyl methacrylate or N-phenyl-maleimide or mixtures thereof characterised in that the butadiene polymer latices (A) and (B) are obtained by seed polymerisation using at least one butadiene polymer latex (C) with a mean particle diameter of 10 to 220 nm, preferably 20 to 210 nm and particularly preferably 30 to 200 nm as seed latex, and the graft rubber component III) is obtained by graft polymerisation in the presence of at least one butadiene polymer latex (C) used as seed latex for (A) and (B).
The present invention also provides a process for producing the polymer com positions according to the invention wherein the butadiene polymer latices (A) and (B) are obtained by seed polymerisation using at least one butadiene polymer latex (C) having a mean particle diameter of 10 to 220 nm as a seed latex and the graft rubber component III) is obtained by graft polymerisation in the presence of at least one butadiene polymer latex (C) used as seed latex for (A) and (B).
In general the polymer compositions according to the invention may contain the graft rubber components (I) and (II) and optionally (III) in arbitrary amounts, preferably in amounts of 1 to 60 parts by weight, particularly preferably in amounts of 5 to parts by weight, and the rubber-free resin component (IV) preferably in amounts of 40 to 99 parts by weight, particularly preferably in amounts of 50 to 95 parts by weight.
The weight ratio of (I):(II):(III) may be varied within wide limits; normally the weight ratio of (I):(II) is 90:10 to 10:90, preferably 80:20 to 20:80 and particularly preferably 70:30 to 35:65, and when (III) is used in addition the weight ratio [(I)+(II)]:(III) is 10:90 to 80:20, preferably 20:80 to 70:30, and particularly preferably 25:75 to 65:35.
Apart from the aforementioned polymer components the polymer compositions according to the invention may contain further rubber-free thermoplastic resins not built up from vinyl monomers, these thermoplastic resins being used in amounts of up to 1000 parts by weight, preferably up to 700 parts by weight and particularly preferably up to 500 parts by weight (in each case referred to 100 parts by weight of I+II+III+IV).
The butadiene polymer latices (A), (B) and (C) are produced by emulsion polymerisation of butadiene according to the so-called seed polymerisation technique, in which first of all a finely particulate polymer, preferably a butadiene polymer, is produced as seed latex and is then polymerised further with butadiene-containing monomers into larger particles (see for example in Houben-Wyl, Methoden der Organischen Chemie, Makromolekulare Stoffe, Part 1, p. 339 (1961), Thieme Verlag Stuttgart). In this connection the process is preferably earned out using a seed batch process or a continuous seed flow process.
As comonomers there may be used up to 50 wt.% (referred to the total amount of monomer used for the butadiene polymer production) of one or more monomers copolymerisable with butadiene.
Examples of such monomers include isoprene, chloroprene, acrylonitrile, styrene, a-methyl styrene, C1-C4-alkylstyrenes, C1-C8-alkyl acrylates, C1-C8-alkyl meth-acrylates, alkylene glycol diacrylates, alkylene glycol dimethacrylates, divinyl benzene; butadiene is preferably used alone or mixed with up to 20 wt.%, preferably with up to 10 wt.%, of styrene and/or acrylonitrile.
As seed latex polymers there are preferably used butadiene polymers such as polybutadiene, butadiene/styrene copolymers, butadiene/acrylonitrile copolymers, or polymers obtained from the aforementioned monomers.
In principle there may also be used other finely particulate latex polymers, for example polystyrene or styrene copolymers, poly(methyl methacrylate) or methyl methacrylate copolymers, as well as polymers of other vinyl monomers.
Preferred seed latex polymers are polybutadiene latices.
In this connection seed latices (C) with a mean particle diameter d5o of 10 to 220 nm, preferably 20 to 210 nm and particularly preferably 30 to 200 nm are used in the production of the butadiene polymer latex (A) and butadiene polymer latex (B).
When using seed lances (C) with mean particle diameters dso above 80 nm, preferably above 90 nm and particularly preferably above 100 nm, the seed latices (C) themselves may also preferably be produced by seed polymerisation. For this purpose there are preferably used seed latices (D) with mean particle diameters dso of to 60 nm, preferably 20 to 50 nm.
The butadiene polymer latex (A) has a mean particle diameter d5o of 230 to 330 nm, preferably 240 to 320 nm and particularly preferably 250 to 310 nm.
The gel content of (A) is 30 to 80 wt.%, preferably 40 to 75 wt.% and particularly preferably 45 to 70 wt.%.
The butadiene polymer latex (B) has a mean particle diameter dso of 340 to 480 nm, preferably 350 to 470 nm, and particularly preferably 360 to 460 nm.
The gel content of (B) is SO to 95 wt.%, preferably 55 to 90 wt.%, and particularly preferably 60 to 85 wt.%.
The butadiene polymer latex (C) has a mean particle diameter dso of 10 to 220 run, preferably 20 to 210 nm, and particularly preferably 30 to 200 nm.
The gel content of (C) is 30 to 98 wt.%, preferably 40 to 95 wt.%, and particularly preferably 50 to 92 wt.%.
The seed latex (D), preferably a butadiene polymer latex, has a mean particle diameter d5o of 10 to 60 nm, preferably 20 to 50 nm.
PCT/EPOl/01493 CA 02400685 2002-08-20 The gel content of (D) is 10 to 95 wt.%, preferably 20 to 90 wt.%, and particularly preferably 30 to 85 wt.%.
The mean particle diameter d5o may be determined by ultracentrifuge measurements (see W. Scholtan, H.' Lange: Kolloid Z. & Z. Polymere 250, p. 782 to 796 (1972)), the specified values for the gel content refernng to the determination according to the wire cage method in toluene (see Houben-Weyl, Methoden der Organischen Chemie, Makromolekulare Stoffe, Part l, p. 307 (1961), Thieme Verlag Stuttgart).
The gel contents of the butadiene polymer lances (A), (B), (C) and (D) may in principle be adjusted in a manner known per se by employing suitable reaction conditions (e.g. high reaction temperature and/or polymerisation up to a high conversion, as well as optionally the addition of crosslinking substances in order to achieve a high gel content, or for example low reaction temperature and/or termi-nation of the polymerisation reaction before too high a degree of crosslinking has occurred, as well as optionally the addition of molecular weight regulators, such as for example n-dodecyl mercaptan or t-dodecyl mercaptan in order to achieve a low gel content). As emulsifiers there may be used conventional anionic emulsifiers such as alkyl sulfates, alkyl sulfonates, aralkyl sulfonates, soaps of saturated or unsaturated fatty acids, as well as alkaline disproportionated or hydrogenated abietinic acid or tall oil acid, and preferably emulsifiers are used containing carboxyl groups (e.g. salts of Clo-Cls fatty acids, disproportionated abietinic acid, emulsifiers according to DE-OS 36 39 904 and DE-OS 39 13 509).
The preparation of the graft rubber polymers (I), (II) and (III) may be carned out in any appropriate manner by separate grafting of the butadiene polymer lances (A), (B) and (C) in separate reactions or by joint grafting of arbitrary mixtures selected from the butadiene polymer latices (A), (B) and (C) during one reaction or two reactions or three reactions.
_7_ In this connection the graft polymerisation(s) may be carned out according to any suitable processes but is/are preferably carried out in such a way that the monomer mixture is continuously added to the butadiene polymer latex (A) and/or to the butadiene polymer latex (B) and/or to the butadiene polymer latex (C) and/or to arbitrary mixtures selected from the butadiene polymer latices (A), (B) and (C), and is polymerised.
In this connection special monomer/rubber ratios are preferably maintained and the monomers are added in a manner known per se to the rubber.
In order to produce the components (I), (II) and (III) according to the invention, preferably 15 to 50 parts by weight, particularly preferably 20 to 40 parts by weight, of a mixture of styrene and acrylonitrile that may optionally contain up to 50 wt.%
(referred to the total amount of the monomers used in the graft polymerisation) of one or more monomers, are polymerised in the presence of 50 to 85 parts by weight, preferably 60 to 80 parts by weight (in each case referred to solids) of the butadiene polymer latex (A) and/or of the butadiene polymer latex (B) and/or of the butadiene polymer latex (C) and/or arbitrary mixtures selected from the butadiene polymer latices (A), (B), and (C).
The monomers used in the graft polymerisation are preferably mixtures of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, particularly preferably in a weight ratio of 80:20 to 65:35, wherein styrene and/or acrylonitrile may be wholly or partially replaced by copolymerisable monomers, preferably by a-methylstyrene, methyl methacrylate or N-phenylinaleimide. In principle arbitrary further copolymerisable vinyl monomers may additionally be used in amounts of up to ca.
10 wt.% (referred to the total amount of the monomers).
In addition molecular weight regulators may be used in the graft polymerisation, preferably in amounts of 0.01 to 2 wt.%, particularly preferably in amounts of 0.05 to _g_ 1 wt.% (in each case referred to the total amount of monomers in the graft polymerisation stage).
Suitable molecular weight regulators are for example alkyl mercaptans such as n-dodecyl mercaptan, t-dodecyl mercaptan; dimeric a-methylstyrene; terpinolene.
Suitable initiators that may be used include inorganic and organic peroxide, e.g.
H202, di-tert.-butyl peroxide, cumene hydroperoxide, dicyclohexyl percarbonate, tert.-butyl hydroperoxide, p-menthane hydroperoxide, azo initiators such as azobisisobutyronitrile, persalts such as ammonium, sodium or potassium persulfate, potassium perphosphate, sodium perborate, as well as redox systems. Redox systems consist as a rule of an organic oxidising agent and a reducing agent, in which connection heavy metal ions may in addition be present in the reaction medium (see Houben-Weyl, Methoden der Organischen Chemie, Vol. 14/1, pp. 263 to 297).
The polymerisation temperature is in general 25°C to 160°C, preferably 40°C to 90°C. Suitable emulsifiers are mentioned above.
The graft polymerisation may be carned out under normal temperature conditions, i.e. isothermally; the graft polymerisation is however preferably carried out so that the temperature difference between the start and end of the reaction is at least 10°C, preferably at least 15°C, and particularly preferably at least 20°C.
In order to produce the components I), II) and III) according to the invention, the graft polymerisation may preferably be carried out by continuous addition of the monomers in such a way that 55 to 90 wt.%, preferably 60 to 80 wt.% and particularly preferably 65 to 75 wt.% of the total amount of monomers used in the graft polymerisation are metered in during the first half of the overall time for metering in the monomers; the remaining proportion of the monomers is metered in within the second half of the overall time for metering in the monomers.
As rubber-free copolymers IV) there are preferably used copolymers of styrene and acrylonitrile in a weight ratio of 9S:S to SO:SO, in which connection styrene and/or acrylonitrile may be wholly or partially replaced by a-methylstyrene, methyl methacrylate or N-phenylmaleimide.
S
Particularly preferred are copolymers IV) containing proportions of incorporated acrylonitrile units of < 30 wt.%.
These copolymers preferably have mean molecular weights M W of 20,000 to 200,000 and intrinsic viscosities [r~] of 20 to 110 ml/g (measured in dimethyl formamide at 2S°C).
Details concerning the production of these resins are described for example in DE-A
Particularly important properties of ABS moulding compositions that may be mentioned include toughness (impact strength, notched impact strength) modulus of elasticity, processability (), Neat resistance, surface gloss, attention being paid to specific prc~perky combinations depending on the area of use.
A particularly important feature for the processing of ABS moulding compositions, particularly when using fully automated production plants, is the constancy of the properties or property combinations of the moulding compositions to be processed.
Although products with relatively narrow tolerance limits can be produced by using modern processes in the ABS production (for example computerised control of polymerisation and compounding), nevertheless for special applications it is necessary to have even more improved constant properties that can be achieved only via the product composition or the product structure.
The object therefore existed of producing thermoplastic moulding compositions of the ABS type that exhibit from batch to batch very constant values for the most important properties also in the case of variations in the individual components that are used. The object according to the invention is achieved by using combinations of special graft rubber polymers in the production of which are employed rubbers with defined particle diameters obtained by seed polymerisation using seed latex particles with defined particle diameters.
The invention provides polymer compositions containing _2_ I) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, styrene and/or acrylonitrile being able to be partially or completely replaced by a-methylstyrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (A) with a mean particle diameter d5o of 230 to 330 nm, preferably 240 to 320 nm, and particularly preferably 250 to 310 nm, II) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, styrene and/or acrylonitrile being able to be completely or partially replaced by a-methyl-styrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (B) with a mean particle diameter d5o of 340 to 480 nm, preferably 350 to 470 nm, and particularly preferably 360 to 460 nm, optionally III) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, wherein styrene and/or acrylonitrile can be wholly or partially replaced by a-methyl styrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (C) and IV) at least one rubber-free copolymer of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, wherein styrene and/or acrylonitrile can be wholly or partially replaced by a-methyl styrene, methyl methacrylate or N-phenyl-maleimide or mixtures thereof characterised in that the butadiene polymer latices (A) and (B) are obtained by seed polymerisation using at least one butadiene polymer latex (C) with a mean particle diameter of 10 to 220 nm, preferably 20 to 210 nm and particularly preferably 30 to 200 nm as seed latex, and the graft rubber component III) is obtained by graft polymerisation in the presence of at least one butadiene polymer latex (C) used as seed latex for (A) and (B).
The present invention also provides a process for producing the polymer com positions according to the invention wherein the butadiene polymer latices (A) and (B) are obtained by seed polymerisation using at least one butadiene polymer latex (C) having a mean particle diameter of 10 to 220 nm as a seed latex and the graft rubber component III) is obtained by graft polymerisation in the presence of at least one butadiene polymer latex (C) used as seed latex for (A) and (B).
In general the polymer compositions according to the invention may contain the graft rubber components (I) and (II) and optionally (III) in arbitrary amounts, preferably in amounts of 1 to 60 parts by weight, particularly preferably in amounts of 5 to parts by weight, and the rubber-free resin component (IV) preferably in amounts of 40 to 99 parts by weight, particularly preferably in amounts of 50 to 95 parts by weight.
The weight ratio of (I):(II):(III) may be varied within wide limits; normally the weight ratio of (I):(II) is 90:10 to 10:90, preferably 80:20 to 20:80 and particularly preferably 70:30 to 35:65, and when (III) is used in addition the weight ratio [(I)+(II)]:(III) is 10:90 to 80:20, preferably 20:80 to 70:30, and particularly preferably 25:75 to 65:35.
Apart from the aforementioned polymer components the polymer compositions according to the invention may contain further rubber-free thermoplastic resins not built up from vinyl monomers, these thermoplastic resins being used in amounts of up to 1000 parts by weight, preferably up to 700 parts by weight and particularly preferably up to 500 parts by weight (in each case referred to 100 parts by weight of I+II+III+IV).
The butadiene polymer latices (A), (B) and (C) are produced by emulsion polymerisation of butadiene according to the so-called seed polymerisation technique, in which first of all a finely particulate polymer, preferably a butadiene polymer, is produced as seed latex and is then polymerised further with butadiene-containing monomers into larger particles (see for example in Houben-Wyl, Methoden der Organischen Chemie, Makromolekulare Stoffe, Part 1, p. 339 (1961), Thieme Verlag Stuttgart). In this connection the process is preferably earned out using a seed batch process or a continuous seed flow process.
As comonomers there may be used up to 50 wt.% (referred to the total amount of monomer used for the butadiene polymer production) of one or more monomers copolymerisable with butadiene.
Examples of such monomers include isoprene, chloroprene, acrylonitrile, styrene, a-methyl styrene, C1-C4-alkylstyrenes, C1-C8-alkyl acrylates, C1-C8-alkyl meth-acrylates, alkylene glycol diacrylates, alkylene glycol dimethacrylates, divinyl benzene; butadiene is preferably used alone or mixed with up to 20 wt.%, preferably with up to 10 wt.%, of styrene and/or acrylonitrile.
As seed latex polymers there are preferably used butadiene polymers such as polybutadiene, butadiene/styrene copolymers, butadiene/acrylonitrile copolymers, or polymers obtained from the aforementioned monomers.
In principle there may also be used other finely particulate latex polymers, for example polystyrene or styrene copolymers, poly(methyl methacrylate) or methyl methacrylate copolymers, as well as polymers of other vinyl monomers.
Preferred seed latex polymers are polybutadiene latices.
In this connection seed latices (C) with a mean particle diameter d5o of 10 to 220 nm, preferably 20 to 210 nm and particularly preferably 30 to 200 nm are used in the production of the butadiene polymer latex (A) and butadiene polymer latex (B).
When using seed lances (C) with mean particle diameters dso above 80 nm, preferably above 90 nm and particularly preferably above 100 nm, the seed latices (C) themselves may also preferably be produced by seed polymerisation. For this purpose there are preferably used seed latices (D) with mean particle diameters dso of to 60 nm, preferably 20 to 50 nm.
The butadiene polymer latex (A) has a mean particle diameter d5o of 230 to 330 nm, preferably 240 to 320 nm and particularly preferably 250 to 310 nm.
The gel content of (A) is 30 to 80 wt.%, preferably 40 to 75 wt.% and particularly preferably 45 to 70 wt.%.
The butadiene polymer latex (B) has a mean particle diameter dso of 340 to 480 nm, preferably 350 to 470 nm, and particularly preferably 360 to 460 nm.
The gel content of (B) is SO to 95 wt.%, preferably 55 to 90 wt.%, and particularly preferably 60 to 85 wt.%.
The butadiene polymer latex (C) has a mean particle diameter dso of 10 to 220 run, preferably 20 to 210 nm, and particularly preferably 30 to 200 nm.
The gel content of (C) is 30 to 98 wt.%, preferably 40 to 95 wt.%, and particularly preferably 50 to 92 wt.%.
The seed latex (D), preferably a butadiene polymer latex, has a mean particle diameter d5o of 10 to 60 nm, preferably 20 to 50 nm.
PCT/EPOl/01493 CA 02400685 2002-08-20 The gel content of (D) is 10 to 95 wt.%, preferably 20 to 90 wt.%, and particularly preferably 30 to 85 wt.%.
The mean particle diameter d5o may be determined by ultracentrifuge measurements (see W. Scholtan, H.' Lange: Kolloid Z. & Z. Polymere 250, p. 782 to 796 (1972)), the specified values for the gel content refernng to the determination according to the wire cage method in toluene (see Houben-Weyl, Methoden der Organischen Chemie, Makromolekulare Stoffe, Part l, p. 307 (1961), Thieme Verlag Stuttgart).
The gel contents of the butadiene polymer lances (A), (B), (C) and (D) may in principle be adjusted in a manner known per se by employing suitable reaction conditions (e.g. high reaction temperature and/or polymerisation up to a high conversion, as well as optionally the addition of crosslinking substances in order to achieve a high gel content, or for example low reaction temperature and/or termi-nation of the polymerisation reaction before too high a degree of crosslinking has occurred, as well as optionally the addition of molecular weight regulators, such as for example n-dodecyl mercaptan or t-dodecyl mercaptan in order to achieve a low gel content). As emulsifiers there may be used conventional anionic emulsifiers such as alkyl sulfates, alkyl sulfonates, aralkyl sulfonates, soaps of saturated or unsaturated fatty acids, as well as alkaline disproportionated or hydrogenated abietinic acid or tall oil acid, and preferably emulsifiers are used containing carboxyl groups (e.g. salts of Clo-Cls fatty acids, disproportionated abietinic acid, emulsifiers according to DE-OS 36 39 904 and DE-OS 39 13 509).
The preparation of the graft rubber polymers (I), (II) and (III) may be carned out in any appropriate manner by separate grafting of the butadiene polymer lances (A), (B) and (C) in separate reactions or by joint grafting of arbitrary mixtures selected from the butadiene polymer latices (A), (B) and (C) during one reaction or two reactions or three reactions.
_7_ In this connection the graft polymerisation(s) may be carned out according to any suitable processes but is/are preferably carried out in such a way that the monomer mixture is continuously added to the butadiene polymer latex (A) and/or to the butadiene polymer latex (B) and/or to the butadiene polymer latex (C) and/or to arbitrary mixtures selected from the butadiene polymer latices (A), (B) and (C), and is polymerised.
In this connection special monomer/rubber ratios are preferably maintained and the monomers are added in a manner known per se to the rubber.
In order to produce the components (I), (II) and (III) according to the invention, preferably 15 to 50 parts by weight, particularly preferably 20 to 40 parts by weight, of a mixture of styrene and acrylonitrile that may optionally contain up to 50 wt.%
(referred to the total amount of the monomers used in the graft polymerisation) of one or more monomers, are polymerised in the presence of 50 to 85 parts by weight, preferably 60 to 80 parts by weight (in each case referred to solids) of the butadiene polymer latex (A) and/or of the butadiene polymer latex (B) and/or of the butadiene polymer latex (C) and/or arbitrary mixtures selected from the butadiene polymer latices (A), (B), and (C).
The monomers used in the graft polymerisation are preferably mixtures of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, particularly preferably in a weight ratio of 80:20 to 65:35, wherein styrene and/or acrylonitrile may be wholly or partially replaced by copolymerisable monomers, preferably by a-methylstyrene, methyl methacrylate or N-phenylinaleimide. In principle arbitrary further copolymerisable vinyl monomers may additionally be used in amounts of up to ca.
10 wt.% (referred to the total amount of the monomers).
In addition molecular weight regulators may be used in the graft polymerisation, preferably in amounts of 0.01 to 2 wt.%, particularly preferably in amounts of 0.05 to _g_ 1 wt.% (in each case referred to the total amount of monomers in the graft polymerisation stage).
Suitable molecular weight regulators are for example alkyl mercaptans such as n-dodecyl mercaptan, t-dodecyl mercaptan; dimeric a-methylstyrene; terpinolene.
Suitable initiators that may be used include inorganic and organic peroxide, e.g.
H202, di-tert.-butyl peroxide, cumene hydroperoxide, dicyclohexyl percarbonate, tert.-butyl hydroperoxide, p-menthane hydroperoxide, azo initiators such as azobisisobutyronitrile, persalts such as ammonium, sodium or potassium persulfate, potassium perphosphate, sodium perborate, as well as redox systems. Redox systems consist as a rule of an organic oxidising agent and a reducing agent, in which connection heavy metal ions may in addition be present in the reaction medium (see Houben-Weyl, Methoden der Organischen Chemie, Vol. 14/1, pp. 263 to 297).
The polymerisation temperature is in general 25°C to 160°C, preferably 40°C to 90°C. Suitable emulsifiers are mentioned above.
The graft polymerisation may be carned out under normal temperature conditions, i.e. isothermally; the graft polymerisation is however preferably carried out so that the temperature difference between the start and end of the reaction is at least 10°C, preferably at least 15°C, and particularly preferably at least 20°C.
In order to produce the components I), II) and III) according to the invention, the graft polymerisation may preferably be carried out by continuous addition of the monomers in such a way that 55 to 90 wt.%, preferably 60 to 80 wt.% and particularly preferably 65 to 75 wt.% of the total amount of monomers used in the graft polymerisation are metered in during the first half of the overall time for metering in the monomers; the remaining proportion of the monomers is metered in within the second half of the overall time for metering in the monomers.
As rubber-free copolymers IV) there are preferably used copolymers of styrene and acrylonitrile in a weight ratio of 9S:S to SO:SO, in which connection styrene and/or acrylonitrile may be wholly or partially replaced by a-methylstyrene, methyl methacrylate or N-phenylmaleimide.
S
Particularly preferred are copolymers IV) containing proportions of incorporated acrylonitrile units of < 30 wt.%.
These copolymers preferably have mean molecular weights M W of 20,000 to 200,000 and intrinsic viscosities [r~] of 20 to 110 ml/g (measured in dimethyl formamide at 2S°C).
Details concerning the production of these resins are described for example in DE-A
2 420 3S8 and DE-A 2 724 360. Vinyl resins produced by bulk polymerisation or 1 S solution polymerisation have proved to be particularly suitable. The copolymers may be added alone or as an arbitrary mixture.
Apart from using thermoplastic resins built up from vinyl monomers, it is also possible to use polycondensates, for example aromatic polycarbonates, aromatic polyester carbonates, polyesters or polyamides as rubber-free copolymer in the moulding compositions according to the invention. Suitable thermoplastic polycarbonates and polyester carbonates are known (see for example DE-A
1 49S 626, DE-A 2 232 877, DE-A 2 703 376, DE-A 2 714 544, DE-A 3 000 610, DE-A 3 832 396, DE-A 3 077 934), which may be prepared for example by reacting 2S diphenols of the formulae (V) and (VI) HO
A ~ . ~ N) Rs ~ Rs n R~ R~
HO ~ ' ~ ~ ~ \ ' ~ OH NI) Rz L ~X)m Rz J
n in which A denotes a single bond C1-CS-alkylene, CZ-CS-alkylidene, CS-C6-cyclo-alkylidene, -O-, -S-, -SO-, -SOz- or -CO-, RS and R6 independently of one another denote hydrogen, methyl or halogen, in particular hydrogen, methyl, chlorine or bromine, R1 and R2 independently of one another denote hydrogen, halogen, preferably chlorine or bromine, Ci-C8-alkyl, preferably methyl, ethyl, CS-C6-cycloalkyl, preferably cyclohexyl, C6-Clo-aryl, preferably phenyl, or C~-Clz-aralkyl, preferably phenyl-C1-C4-alkyl, in particular benzyl, m is an integer from 4 to 7, preferably 4 or S, n is 0 or 1, R3 and R4 may be selected individually for each X and independently of one another denote hydrogen or C1-C6-alkyl, and X denotes carbon, with carbonic acid halides, preferably phosgene, and/or with aromatic dicarboxylic acid dihalides, preferably benzenedicarboxylic acid dihalides, by phase boundary polycondensation, or with phosgene by polycondensation in the homogeneous phase (so-called pyridine process), in which connection the molecular weight may be adjusted in a manner known per se by adding an appropriate amount of known chain terminators.
Suitable diphenols of the formulae (V) and (VI) are for example hydroquinone, resorcinol, 4,4'-dihydroxydiphenyl, 2,2-bis-(4-hydroxyphenyl)-propane, 2,4-bis-(4-hydroxyphenyl)-2-methylbutane, 2,2-bis-(4-hydroxy-3,5-dimethylphenyl)-propane, 2,2-bis-(4-hydroxy-3,5-dichlorophenyl)-propane, 2,2-bis-(4-hydroxy-3,5-dibromo-phenyl)-propane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, 1,1-bis-(4-hydroxy-phenyl)-3,3,5-trimethylcyclohexane, l,l-bis-(4-hydroxyphenyl)-3,3-dimethylcyclo-hexane, 1,1-bis-(4-hydroxyphenyl)-3,3,5,5-tetramethylcyclohexane or 1,1-bis-(4-hydroxyphenyl)-2,4,4,-trimethylcyclopentane.
Preferred diphenols of the formula (V) are 2,2-bis-(4-hyroxyphenyl)-propane and 1,1-bis-(4-hydroxyphenyl)-cyclohexane, and the preferred phenol of the formula (VI) is 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.
Mixtures of diphenols may also be used.
Suitable chain terminators are for example phenol, p-tert.-butylphenol, long-chain alkyl phenols such as 4-(1,3-tetramethylbutyl)phenol according to DE-A 2 842 005, monoalkylphenols, dialkylphenols having a total of 8 to 20 C atoms in the alkyl substituents according to DE-A 3 506 472, such as p-nonylphenol, 2,5-di-tert.-butyl-phenol, p-tert.-octylphenol, p-dodecylphenol, 2-(3,5-dimethylheptyl)-phenol and 4-(3,5-dimethylheptyl)-phenol. The necessary amount of chain terminators is generally 0.5 to 10 mole % referred to the sum of the diphenols (V) and (VI).
The suitable polycarbonates or polyester carbonates may be linear or branched;
preferred products are preferably obtained by incorporating 0.05 to 2.0 mole %, referred to the sum of the diphenols employed, of trifunctional or higher functionality compounds, for example those having three or more than three phenolic OH
groups.
The suitable polycarbonates or polyester carbonates may contain aromatically bound halogen, preferably bromine and/or chlorine; however, they are preferably halogen-free.
S
The polycarbonates and polyester carbonates have mean molecular weights ( M W, weight average), determined for example by ultracentrifugation or light scattering measurements, of 10,000 to 200,000, preferably 20,000 to 80,000.
Suitable thermoplastic polyesters are preferably polyalkylene terephthalates, i.e.
reaction products of aromatic dicarboxylic acids or their reactive derivatives (e.g.
dimethyl esters or anhydrides) with aliphatic, cycloaliphatic or arylaliphatic diols and mixtures of such reaction products.
1 S Preferred polyalkylene terephthalates can be prepared from terephthalic acids (or their reactive derivatives) and aliphatic or cycloaliphatic diols with 2 to 10 C atoms according to known methods (Kunststoff Handbuch, Vol. VIII, p. 695 et seq.
Carl Hanser Verlag, Munich 1973).
In preferred polyalkylene terephthalates 80 to 100 mole %, preferably 90 to mole % of the dicarboxylic acid residues are terephthalic acid residues, and 80 to 100 mole %, preferably 90 to 100 mole % of the diol residues are ethylene glycol residues and/or butanediol-1,4 residues.
The preferred polyalkylene terephthalates may in addition to ethylene glycol residues and/or butanediol-1,4 residues also contain 0 to 20 mole % of residues of other aliphatic diols with 3 to 12 C atoms or cycloaliphatic diols with 6 to 12 C
atoms, for example residues of propanediol-1,3, 2-ethylpropanediol-1,3, neopentyl glycol, pentanediol-1,5, hexanediol-1,6, cyclohexanedimethanol-1,4, 3-methylpentanediol-1,3 and -1,6, 2-ethylhexanediol-1,3, 2,2-diethylpropanediol-1,3, hexanediol-2,5, 1,4-di((3-hydroxyethoxy)-benzene, 2,2-bis-4-(hydroxycyclohexyl)-propane, 2,4-dihy-droxy-1,1,3,3-tetramethylcyclobutane, 2,2-bis-(3-(3-hydroxyethoxyphenyl)-propane and 2,2-bis-(4-hydroxypropoxyphenyl)-propane (DE-OS 2 407 647, 2 407 776, 2 715 932).
The polyalkylene terephthalates may be branched by incorporating relatively small amounts of trihydroxy or tetrahydroxy alcohols or 3-basic ar 4-basic carboxylic acids, as are described in DE-OS 1 900 270 and in US-A 3 692 744. Examples of preferred branching agents are trimesic acid, trimellitic acid, trimethylol ethane and trimethylol propane, and pentaerythritol. It is advisable to use not more than 1 mole % of the branching agent, referred to the acid component.
Particularly preferred are polyalkylene terephthalates that have been produced solely from terephthalic acid and its reactive derivatives (for example its dialkyl esters) and ethylene glycol and/or butanediol-1,4, and mixtures of these polyalkylene tere-phthalates.
Preferred polyalkylene terephthalates are also copolyesters that have been prepared from at least two of the abovementioned alcohol components: particularly preferred copolyesters are poly(ethyleneglycolbutanediol-1,4)-terephthalates.
The preferably suitable polyalkylene terephthalates generally have an intrinsic viscosity of 0.4 to 1.5 dl/g, preferably 0.5 to 1.3 dl/g, in particular 0.6 to 1.2 dl/g, measured in each case in phenol/o-dichlorobenzene (1:1 parts by weight) at 25°C.
Suitable polyamides are known homopolyamides, copolyamides and mixtures of these polyamides. These polyamides may be partially crystalline and/or amorphous.
Suitable partially crystalline polyamides are polyamide-6, polyamide-6,6, mixtures and corresponding copolymers prepared from these components. Also suitable are partially crystalline polyamides whose acid component consists wholly or partially of terephthalic acid and/or isophthalic acid and/or cork acid and/or sebacic acid and/or azelaic acid and/or adipic acid and/or cyclohexanedicarboxylic acid, whose diamine component consists wholly or partially of m- and/or p-xylylene diamine and/or hexamethylene diamine and/or 2,2,4-trimethylhexamethylene diamine and/or 2,2,4 trimethylhexamethylene diamine and/or isophorone diamine, and whose composition is in principle known.
There may also be mentioned polyamides that have been produced wholly or partially from lactams with 7 to 12 C atoms in the ring, optionally with the co-use of one or more of the abovementioned starting components.
Particularly preferred partially crystalline polyamides are polyamide-6 and polyamide-6,6 and their mixtures. As amorphous polyamides there may be used known products that are obtained by polycondensation of diamines such as ethylene diamine, hexamethylene diamine, decamethylene diamine, 2,2,4- and/or 2,4,4-trimethylhexamethylene diamine, m- and/or p-xylylene diamine, bis-(4-amino-cyclohexyl)-methane, bis-(4-aminocyclohexyl)-propane, 3,3'-dimethyl-4,4'-diamino-dicyclohexylinethane, 3-aminomethyl-3,5,5,-trimethylcyclohexylamine, 2,5-and/or 2,6-bis-(aminomethyl)-norbornane and/or 1,4-diaminomethylcyclohexane with dicarboxylic acids such as oxalic acid, adipic acid, azelaic acid, decanedicarboxylic acid, heptadecanedicarboxylic acid, 2,2,4- and/or 2,4,4-trimethyladipic acid, isophthalic acid and terephthalic acid.
Also suitable are copolymers obtained by polycondensation of several monomers, as well as copolymers prepared with the addition of aminocarboxylic acids such as E-aminocaproic acid, c~-aminoundecanoic acid or w-aminolauric acid or their lactams.
Particularly suitable amorphous polyamides are the polyamides prepared from isophthalic acid, hexamethylene diamine and further diamines such as 4,4'-diamino-dicyclohexylmethane, isophorone, 2,2,4- and/or 2,4,4-trimethylhexamethylene diamine, 2,5- and/or 2,6-bis-(aminomethyl)-nobornene; or from isophthalic acid, 4,4'-diaminodicyclohexylmethane and s-caprolactam; or from isophthalic acid, 3,3'-dimethyl-4,4'-diaminodicyclohexylmethane and laurinlactam; or from terephthalic acid and the isomeric mixture of 2,2,4- and/or 2,4,4-trimethylhexamethylene diamine.
Instead of the pure 4,4'-diaminodicyclohexylmethane, mixtures of the positional isomeric diaminodicyclohexylinethanes that are composed of the following components may also be used 70 to 99 mole % of the 4,4'-diamino isomer 1 to 30 mole % of the 2,4'-diamino isomer 0 to 2 mole % of the 2,2'-diamino isomer, and optionally correspondingly higher condensed diamines that are obtained by hydrogenating industrial quality diaminodiphenylmethane. The isophthalic acid may be replaced in an amount of up to 30% by terephthalic acid.
The polyamides preferably have a relative viscosity (measured in a 1 wt.%
solution in m-cresol at 25°C) of 2.0 to 5.0, particularly preferably 2.5 to 4Ø
Preferred moulding compositions according to the invention contain 1 to 60 parts by weight, preferably S to 50 parts by weight of the graft polymer components I), II) and III), and 40 to 99 parts by weight, preferably 50 to 95 parts by weight, of rubber-free copolymer.
The production of the moulding compositions according to the invention is earned out by mixing the components I), II) and III) and IV) in conventional mixing units (preferably in multiple roll mills, mixing extruders or internal kneaders).
The invention accordingly also provides a process for producing the moulding compositions according to the invention, wherein the components I), II) and III) and IV) are mixed and compounded at elevated temperature, in general at temperatures of 150°C to 300°C, and are then extruded.
PCT/EPOl/01493 CA 02400685 2002-08-20 Necessary and/or advantageous additives, for example antioxidants, UV
stabilisers, peroxide destroyers, antistatic agents, lubricating agents, mould release agents, flame protection agents, fillers or reinforcing materials (glass fibres, carbon fibres etc.) and pigments may be added to the moulding compositions according to the invention during the production, processing, further processing and final shaping stages.
The final shaping may be carned out in conventional processing units, and includes for example processing by injection moulding, sheet extrusion optionally followed by heat forming, cold forming, extrusion of pipes and profiled sections, and calender processing.
In the following examples the specified parts are always parts by weight and the specified % are always wt. % unless otherwise stated.
PCT/EPOl/01493 CA 02400685 2002-08-20 Examples Components ABS graft polymer 1 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 289 mn and a gel content of 66 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 118 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 399 mn and a gel content of 80 wt.% and produced by free-radical seed poly-merisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 2 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 289 nm and a gel content of 66 wt.%, produced by free-radical seed polymerisation using a polybutadiene latex with a mean particle diameter d5o of 118 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 410 nm and a gel content of 85 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 118 nm, are adjusted with water to a solids content of ca. 20 wt.%, then heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 3 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 289 nm and a gel content of 66 wt.%, produced by free-radical seed polymerisation using a polybutadiene latex with a mean particle diameter dso of 118 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 456 nm and a gel content of 76 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 4 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 289 nm and a gel content of 66 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter d5o of 118 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 445 run and a gel content of 84 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within b hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After PCT/EPO1/01493 cA 02400685 2002-08-20 a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS draft polymer 5 (comparison) The "ABS graft polymer 1" instructions are repeated, wherein a mixture of polybutadiene lances that have in each case been produced without using seed latex is employed (29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter d5o of 299 nm and a gel content of 70 wt.%, and 29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter dso of 391 nm and a gel content of 80 wt.%).
ABS draft polymer 6 (comparison) The "ABS graft polymer 2" instructions are repeated, wherein a mixture of poly-butadiene latices that have in each case been produced without using seed latex is employed (29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter d5o of 299 nm and a gel content of 70 wt.%, and 29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter dso of 416 nm and a gel content of 87 wt.%).
ABS draft polymer 7 (comparison) The "ABS graft polymer 3" instructions are repeated, wherein a mixture of poly-butadiene latices that have in each case been produced without using seed latex is employed (29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter dso of 282 nm and a gel content of 49 wt.%, and 29 parts by weight of polybutadiene Iatex (calculated as solids) with a mean particle diameter dso of 432 nm and a gel content of 81 wt.%).
ABS graft polymer 8 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 305 nm and a gel content of 55 wt.%, produced by free-radical seed polymerisation using a polybutadiene latex with a mean particle diameter dso of 111 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 404 nm and a gel content of 81 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 9 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 305 nm and a gel content of 55 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 111 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 405 nm and a gel content of 75 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are PCT/EPOl/01493 CA 02400685 2002-08-20 adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 10 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 305 nm and a gel content of 55 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 111 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 412 nm and a gel content of 84 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After PCT/EPOl/01493 CA 02400685 2002-08-20 a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 11 (according to the invention) 50 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 137 run and a gel content of 88 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 48 nm are adjusted with water to a solids content of ca.
wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
50 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 15 0.15 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After 20 a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
Resin component 1 Statistical styrene/acrylonitrile copolymer (styrene:acrylonitrile weight ratio 72:28) with a M W of ca. 115,000 and M W / M" - 1<_2 obtained by free-radical solution polymerisation.
Resin component Z
Statistical styrene/acrylonitrile copolymer (styrene:acrylonitrile weight ratio 72:28) with a M W of ca. 85,000 and M W / M" - 1<_2 obtained by free-radical solution polymerisation.
Moulding compositions The aforedescribed polymer components are mixed in an internal kneader in the proportions given in Table 1 together with 2 parts by weight of ethylenediamine bisstearyl amide and 0.1 part by weight of a silicone oil and after granulation are processed into test pieces.
The following data are obtained:
notched impact strength at room temperature (akRT) and at -40°C
(ak~°~o) according to ISO 180/1A (unit: kJ/m2), ball indentation hardness (Hc) according to DIN
(unit: N/mm2), thermoplastic flow (MVI) according to DIN 53 735 U (unit:
cm3/10 min).
It is clear from the Examples (test data see Table 2) that the products according to the invention exhibit very narrow fluctuation ranges in the most important properties (in particular toughness and processability).
Although the comparison products exhibit similar absolute values for the tested properties, the fluctuation ranges are however much greater.
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N M ~ ~n ~ l~ o0 01 PCT/EPOl/01493 CA 02400685 2002-08-20 Table 2: Test data of the moulding compositions Example akRT ak a0C gc MVI
(kJ/m2) (kJ/mz) (N/mm2) (cm3/lOmin) 1 31:2 21.3 81 9.6 2 30.7 21.3 81 9.6 3 31.1 21.3 80 9.4 4 30.9 21.7 81 9.3 (Comparison) 31.1 19.9 81 7.5 6 (Comparison) 29.1 17.9 84 8.7 7 (Comparison) 33.4 15.3 88 9.2 8 17.5 8.6 114 33.4 9 16.9 8.9 114 33.9 17.0 9.2 113 33.7
Apart from using thermoplastic resins built up from vinyl monomers, it is also possible to use polycondensates, for example aromatic polycarbonates, aromatic polyester carbonates, polyesters or polyamides as rubber-free copolymer in the moulding compositions according to the invention. Suitable thermoplastic polycarbonates and polyester carbonates are known (see for example DE-A
1 49S 626, DE-A 2 232 877, DE-A 2 703 376, DE-A 2 714 544, DE-A 3 000 610, DE-A 3 832 396, DE-A 3 077 934), which may be prepared for example by reacting 2S diphenols of the formulae (V) and (VI) HO
A ~ . ~ N) Rs ~ Rs n R~ R~
HO ~ ' ~ ~ ~ \ ' ~ OH NI) Rz L ~X)m Rz J
n in which A denotes a single bond C1-CS-alkylene, CZ-CS-alkylidene, CS-C6-cyclo-alkylidene, -O-, -S-, -SO-, -SOz- or -CO-, RS and R6 independently of one another denote hydrogen, methyl or halogen, in particular hydrogen, methyl, chlorine or bromine, R1 and R2 independently of one another denote hydrogen, halogen, preferably chlorine or bromine, Ci-C8-alkyl, preferably methyl, ethyl, CS-C6-cycloalkyl, preferably cyclohexyl, C6-Clo-aryl, preferably phenyl, or C~-Clz-aralkyl, preferably phenyl-C1-C4-alkyl, in particular benzyl, m is an integer from 4 to 7, preferably 4 or S, n is 0 or 1, R3 and R4 may be selected individually for each X and independently of one another denote hydrogen or C1-C6-alkyl, and X denotes carbon, with carbonic acid halides, preferably phosgene, and/or with aromatic dicarboxylic acid dihalides, preferably benzenedicarboxylic acid dihalides, by phase boundary polycondensation, or with phosgene by polycondensation in the homogeneous phase (so-called pyridine process), in which connection the molecular weight may be adjusted in a manner known per se by adding an appropriate amount of known chain terminators.
Suitable diphenols of the formulae (V) and (VI) are for example hydroquinone, resorcinol, 4,4'-dihydroxydiphenyl, 2,2-bis-(4-hydroxyphenyl)-propane, 2,4-bis-(4-hydroxyphenyl)-2-methylbutane, 2,2-bis-(4-hydroxy-3,5-dimethylphenyl)-propane, 2,2-bis-(4-hydroxy-3,5-dichlorophenyl)-propane, 2,2-bis-(4-hydroxy-3,5-dibromo-phenyl)-propane, 1,1-bis-(4-hydroxyphenyl)-cyclohexane, 1,1-bis-(4-hydroxy-phenyl)-3,3,5-trimethylcyclohexane, l,l-bis-(4-hydroxyphenyl)-3,3-dimethylcyclo-hexane, 1,1-bis-(4-hydroxyphenyl)-3,3,5,5-tetramethylcyclohexane or 1,1-bis-(4-hydroxyphenyl)-2,4,4,-trimethylcyclopentane.
Preferred diphenols of the formula (V) are 2,2-bis-(4-hyroxyphenyl)-propane and 1,1-bis-(4-hydroxyphenyl)-cyclohexane, and the preferred phenol of the formula (VI) is 1,1-bis-(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane.
Mixtures of diphenols may also be used.
Suitable chain terminators are for example phenol, p-tert.-butylphenol, long-chain alkyl phenols such as 4-(1,3-tetramethylbutyl)phenol according to DE-A 2 842 005, monoalkylphenols, dialkylphenols having a total of 8 to 20 C atoms in the alkyl substituents according to DE-A 3 506 472, such as p-nonylphenol, 2,5-di-tert.-butyl-phenol, p-tert.-octylphenol, p-dodecylphenol, 2-(3,5-dimethylheptyl)-phenol and 4-(3,5-dimethylheptyl)-phenol. The necessary amount of chain terminators is generally 0.5 to 10 mole % referred to the sum of the diphenols (V) and (VI).
The suitable polycarbonates or polyester carbonates may be linear or branched;
preferred products are preferably obtained by incorporating 0.05 to 2.0 mole %, referred to the sum of the diphenols employed, of trifunctional or higher functionality compounds, for example those having three or more than three phenolic OH
groups.
The suitable polycarbonates or polyester carbonates may contain aromatically bound halogen, preferably bromine and/or chlorine; however, they are preferably halogen-free.
S
The polycarbonates and polyester carbonates have mean molecular weights ( M W, weight average), determined for example by ultracentrifugation or light scattering measurements, of 10,000 to 200,000, preferably 20,000 to 80,000.
Suitable thermoplastic polyesters are preferably polyalkylene terephthalates, i.e.
reaction products of aromatic dicarboxylic acids or their reactive derivatives (e.g.
dimethyl esters or anhydrides) with aliphatic, cycloaliphatic or arylaliphatic diols and mixtures of such reaction products.
1 S Preferred polyalkylene terephthalates can be prepared from terephthalic acids (or their reactive derivatives) and aliphatic or cycloaliphatic diols with 2 to 10 C atoms according to known methods (Kunststoff Handbuch, Vol. VIII, p. 695 et seq.
Carl Hanser Verlag, Munich 1973).
In preferred polyalkylene terephthalates 80 to 100 mole %, preferably 90 to mole % of the dicarboxylic acid residues are terephthalic acid residues, and 80 to 100 mole %, preferably 90 to 100 mole % of the diol residues are ethylene glycol residues and/or butanediol-1,4 residues.
The preferred polyalkylene terephthalates may in addition to ethylene glycol residues and/or butanediol-1,4 residues also contain 0 to 20 mole % of residues of other aliphatic diols with 3 to 12 C atoms or cycloaliphatic diols with 6 to 12 C
atoms, for example residues of propanediol-1,3, 2-ethylpropanediol-1,3, neopentyl glycol, pentanediol-1,5, hexanediol-1,6, cyclohexanedimethanol-1,4, 3-methylpentanediol-1,3 and -1,6, 2-ethylhexanediol-1,3, 2,2-diethylpropanediol-1,3, hexanediol-2,5, 1,4-di((3-hydroxyethoxy)-benzene, 2,2-bis-4-(hydroxycyclohexyl)-propane, 2,4-dihy-droxy-1,1,3,3-tetramethylcyclobutane, 2,2-bis-(3-(3-hydroxyethoxyphenyl)-propane and 2,2-bis-(4-hydroxypropoxyphenyl)-propane (DE-OS 2 407 647, 2 407 776, 2 715 932).
The polyalkylene terephthalates may be branched by incorporating relatively small amounts of trihydroxy or tetrahydroxy alcohols or 3-basic ar 4-basic carboxylic acids, as are described in DE-OS 1 900 270 and in US-A 3 692 744. Examples of preferred branching agents are trimesic acid, trimellitic acid, trimethylol ethane and trimethylol propane, and pentaerythritol. It is advisable to use not more than 1 mole % of the branching agent, referred to the acid component.
Particularly preferred are polyalkylene terephthalates that have been produced solely from terephthalic acid and its reactive derivatives (for example its dialkyl esters) and ethylene glycol and/or butanediol-1,4, and mixtures of these polyalkylene tere-phthalates.
Preferred polyalkylene terephthalates are also copolyesters that have been prepared from at least two of the abovementioned alcohol components: particularly preferred copolyesters are poly(ethyleneglycolbutanediol-1,4)-terephthalates.
The preferably suitable polyalkylene terephthalates generally have an intrinsic viscosity of 0.4 to 1.5 dl/g, preferably 0.5 to 1.3 dl/g, in particular 0.6 to 1.2 dl/g, measured in each case in phenol/o-dichlorobenzene (1:1 parts by weight) at 25°C.
Suitable polyamides are known homopolyamides, copolyamides and mixtures of these polyamides. These polyamides may be partially crystalline and/or amorphous.
Suitable partially crystalline polyamides are polyamide-6, polyamide-6,6, mixtures and corresponding copolymers prepared from these components. Also suitable are partially crystalline polyamides whose acid component consists wholly or partially of terephthalic acid and/or isophthalic acid and/or cork acid and/or sebacic acid and/or azelaic acid and/or adipic acid and/or cyclohexanedicarboxylic acid, whose diamine component consists wholly or partially of m- and/or p-xylylene diamine and/or hexamethylene diamine and/or 2,2,4-trimethylhexamethylene diamine and/or 2,2,4 trimethylhexamethylene diamine and/or isophorone diamine, and whose composition is in principle known.
There may also be mentioned polyamides that have been produced wholly or partially from lactams with 7 to 12 C atoms in the ring, optionally with the co-use of one or more of the abovementioned starting components.
Particularly preferred partially crystalline polyamides are polyamide-6 and polyamide-6,6 and their mixtures. As amorphous polyamides there may be used known products that are obtained by polycondensation of diamines such as ethylene diamine, hexamethylene diamine, decamethylene diamine, 2,2,4- and/or 2,4,4-trimethylhexamethylene diamine, m- and/or p-xylylene diamine, bis-(4-amino-cyclohexyl)-methane, bis-(4-aminocyclohexyl)-propane, 3,3'-dimethyl-4,4'-diamino-dicyclohexylinethane, 3-aminomethyl-3,5,5,-trimethylcyclohexylamine, 2,5-and/or 2,6-bis-(aminomethyl)-norbornane and/or 1,4-diaminomethylcyclohexane with dicarboxylic acids such as oxalic acid, adipic acid, azelaic acid, decanedicarboxylic acid, heptadecanedicarboxylic acid, 2,2,4- and/or 2,4,4-trimethyladipic acid, isophthalic acid and terephthalic acid.
Also suitable are copolymers obtained by polycondensation of several monomers, as well as copolymers prepared with the addition of aminocarboxylic acids such as E-aminocaproic acid, c~-aminoundecanoic acid or w-aminolauric acid or their lactams.
Particularly suitable amorphous polyamides are the polyamides prepared from isophthalic acid, hexamethylene diamine and further diamines such as 4,4'-diamino-dicyclohexylmethane, isophorone, 2,2,4- and/or 2,4,4-trimethylhexamethylene diamine, 2,5- and/or 2,6-bis-(aminomethyl)-nobornene; or from isophthalic acid, 4,4'-diaminodicyclohexylmethane and s-caprolactam; or from isophthalic acid, 3,3'-dimethyl-4,4'-diaminodicyclohexylmethane and laurinlactam; or from terephthalic acid and the isomeric mixture of 2,2,4- and/or 2,4,4-trimethylhexamethylene diamine.
Instead of the pure 4,4'-diaminodicyclohexylmethane, mixtures of the positional isomeric diaminodicyclohexylinethanes that are composed of the following components may also be used 70 to 99 mole % of the 4,4'-diamino isomer 1 to 30 mole % of the 2,4'-diamino isomer 0 to 2 mole % of the 2,2'-diamino isomer, and optionally correspondingly higher condensed diamines that are obtained by hydrogenating industrial quality diaminodiphenylmethane. The isophthalic acid may be replaced in an amount of up to 30% by terephthalic acid.
The polyamides preferably have a relative viscosity (measured in a 1 wt.%
solution in m-cresol at 25°C) of 2.0 to 5.0, particularly preferably 2.5 to 4Ø
Preferred moulding compositions according to the invention contain 1 to 60 parts by weight, preferably S to 50 parts by weight of the graft polymer components I), II) and III), and 40 to 99 parts by weight, preferably 50 to 95 parts by weight, of rubber-free copolymer.
The production of the moulding compositions according to the invention is earned out by mixing the components I), II) and III) and IV) in conventional mixing units (preferably in multiple roll mills, mixing extruders or internal kneaders).
The invention accordingly also provides a process for producing the moulding compositions according to the invention, wherein the components I), II) and III) and IV) are mixed and compounded at elevated temperature, in general at temperatures of 150°C to 300°C, and are then extruded.
PCT/EPOl/01493 CA 02400685 2002-08-20 Necessary and/or advantageous additives, for example antioxidants, UV
stabilisers, peroxide destroyers, antistatic agents, lubricating agents, mould release agents, flame protection agents, fillers or reinforcing materials (glass fibres, carbon fibres etc.) and pigments may be added to the moulding compositions according to the invention during the production, processing, further processing and final shaping stages.
The final shaping may be carned out in conventional processing units, and includes for example processing by injection moulding, sheet extrusion optionally followed by heat forming, cold forming, extrusion of pipes and profiled sections, and calender processing.
In the following examples the specified parts are always parts by weight and the specified % are always wt. % unless otherwise stated.
PCT/EPOl/01493 CA 02400685 2002-08-20 Examples Components ABS graft polymer 1 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 289 mn and a gel content of 66 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 118 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 399 mn and a gel content of 80 wt.% and produced by free-radical seed poly-merisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 2 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 289 nm and a gel content of 66 wt.%, produced by free-radical seed polymerisation using a polybutadiene latex with a mean particle diameter d5o of 118 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 410 nm and a gel content of 85 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 118 nm, are adjusted with water to a solids content of ca. 20 wt.%, then heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 3 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 289 nm and a gel content of 66 wt.%, produced by free-radical seed polymerisation using a polybutadiene latex with a mean particle diameter dso of 118 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 456 nm and a gel content of 76 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 4 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 289 nm and a gel content of 66 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter d5o of 118 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 445 run and a gel content of 84 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within b hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After PCT/EPO1/01493 cA 02400685 2002-08-20 a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS draft polymer 5 (comparison) The "ABS graft polymer 1" instructions are repeated, wherein a mixture of polybutadiene lances that have in each case been produced without using seed latex is employed (29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter d5o of 299 nm and a gel content of 70 wt.%, and 29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter dso of 391 nm and a gel content of 80 wt.%).
ABS draft polymer 6 (comparison) The "ABS graft polymer 2" instructions are repeated, wherein a mixture of poly-butadiene latices that have in each case been produced without using seed latex is employed (29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter d5o of 299 nm and a gel content of 70 wt.%, and 29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter dso of 416 nm and a gel content of 87 wt.%).
ABS draft polymer 7 (comparison) The "ABS graft polymer 3" instructions are repeated, wherein a mixture of poly-butadiene latices that have in each case been produced without using seed latex is employed (29 parts by weight of polybutadiene latex (calculated as solids) with a mean particle diameter dso of 282 nm and a gel content of 49 wt.%, and 29 parts by weight of polybutadiene Iatex (calculated as solids) with a mean particle diameter dso of 432 nm and a gel content of 81 wt.%).
ABS graft polymer 8 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 305 nm and a gel content of 55 wt.%, produced by free-radical seed polymerisation using a polybutadiene latex with a mean particle diameter dso of 111 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 404 nm and a gel content of 81 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 9 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 305 nm and a gel content of 55 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 111 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 405 nm and a gel content of 75 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are PCT/EPOl/01493 CA 02400685 2002-08-20 adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 10 (according to the invention) 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 305 nm and a gel content of 55 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 111 nm, and 29 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter dso of 412 nm and a gel content of 84 wt.% produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 137 nm, are adjusted with water to a solids content of ca. 20 wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
42 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 0.12 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After PCT/EPOl/01493 CA 02400685 2002-08-20 a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
ABS graft polymer 11 (according to the invention) 50 parts by weight (calculated as solids) of an anionically emulsified polybutadiene latex with a mean particle diameter d5o of 137 run and a gel content of 88 wt.%, produced by free-radical seed polymerisation using a polybutadiene seed latex with a mean particle diameter dso of 48 nm are adjusted with water to a solids content of ca.
wt.%, heated to 59°C, following which 0.5 part by weight of potassium peroxodisulfate (dissolved in water) is added.
50 parts by weight of a mixture of 73 wt.% of styrene, 27 wt.% of acrylonitrile and 15 0.15 part by weight of tert.-dodecyl mercaptan are then metered in uniformly within 6 hours; parallel to this 1 part by weight (calculated as solids) of the sodium salt of a resin acid mixture (Dresinate 731, Abieta Chemie GmbH, Gersthofen, Germany, dissolved in alkaline adjusted water) is metered in over a period of 6 hours.
During the course of the 6 hours the reaction temperature is raised from 59°C
to 80°C. After 20 a post-reaction time of 2 hours at 80°C the graft latex is coagulated, after adding ca.
1.0 part by weight of a phenolic antioxidant, with a magnesium sulfate/acetic acid mixture, and after washing with water the resultant moist powder is dried at 70°C.
Resin component 1 Statistical styrene/acrylonitrile copolymer (styrene:acrylonitrile weight ratio 72:28) with a M W of ca. 115,000 and M W / M" - 1<_2 obtained by free-radical solution polymerisation.
Resin component Z
Statistical styrene/acrylonitrile copolymer (styrene:acrylonitrile weight ratio 72:28) with a M W of ca. 85,000 and M W / M" - 1<_2 obtained by free-radical solution polymerisation.
Moulding compositions The aforedescribed polymer components are mixed in an internal kneader in the proportions given in Table 1 together with 2 parts by weight of ethylenediamine bisstearyl amide and 0.1 part by weight of a silicone oil and after granulation are processed into test pieces.
The following data are obtained:
notched impact strength at room temperature (akRT) and at -40°C
(ak~°~o) according to ISO 180/1A (unit: kJ/m2), ball indentation hardness (Hc) according to DIN
(unit: N/mm2), thermoplastic flow (MVI) according to DIN 53 735 U (unit:
cm3/10 min).
It is clear from the Examples (test data see Table 2) that the products according to the invention exhibit very narrow fluctuation ranges in the most important properties (in particular toughness and processability).
Although the comparison products exhibit similar absolute values for the tested properties, the fluctuation ranges are however much greater.
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N M ~ ~n ~ l~ o0 01 PCT/EPOl/01493 CA 02400685 2002-08-20 Table 2: Test data of the moulding compositions Example akRT ak a0C gc MVI
(kJ/m2) (kJ/mz) (N/mm2) (cm3/lOmin) 1 31:2 21.3 81 9.6 2 30.7 21.3 81 9.6 3 31.1 21.3 80 9.4 4 30.9 21.7 81 9.3 (Comparison) 31.1 19.9 81 7.5 6 (Comparison) 29.1 17.9 84 8.7 7 (Comparison) 33.4 15.3 88 9.2 8 17.5 8.6 114 33.4 9 16.9 8.9 114 33.9 17.0 9.2 113 33.7
Claims (9)
1. Polymer compositions comprising I) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, styrene and/or acrylonitrile being able to be partially or completely replaced by .alpha.-methylstyrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (A) with a mean particle diameter d50 of 230 to 330 nm, II) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, styrene and/or acrylonitrile being able to be completely or partially replaced by .alpha.-methylstyrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (B) with a mean particle diameter d50 of 340 to 480 nm, III) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, wherein styrene and/or acrylonitrile can be wholly or partially replaced by .alpha.-methyl styrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (C) and IV) at least one rubber-free copolymer of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50 wherein styrene and/or acrylonitrile can be wholly or partially replaced by .alpha.-methyl styrene, methyl meth-acrylate or N-phenylmaleimide or mixtures thereof, characterised in that the butadiene polymer lances (A) and (B) were obtained by seed polymerisation using at least one butadiene polymer latex (C) with a mean particle diameter of 10 to 220 nm as seed latex, and the graft rubber component III) was obtained by graft polymerisation in the presence of at least one butadiene polymer latex (C) used as seed latex for (A) and (B).
2. Polymer compositions according to claim 1 comprising I) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, styrene and/or acrylonitrile being able to be partially or completely replaced by .alpha.-methylstyrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (A) with a mean particle diameter d50 of 240 to 320 nm, II) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, styrene and/or acrylonitrile being able to be completely or partially replaced by .alpha.-methylstyrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (B) with a mean particle diameter d50 of 350 to 470 nm, optionally III) at least one graft rubber polymer obtained by emulsion polymerisation of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50, wherein styrene and/or acrylonitrile can be wholly or partially replaced by .alpha.-methyl styrene, methyl methacrylate or N-phenylmaleimide or mixtures thereof, in the presence of a butadiene polymer latex (C) and IV) at least one rubber-free copolymer of styrene and acrylonitrile in a weight ratio of 95:5 to 50:50 wherein styrene and/or acrylonitrile can be wholly or partially replaced by .alpha.-methyl styrene, methyl meth-acrylate or N-phenyl-maleimide or mixtures thereof characterised in that the butadiene polymer latices (A) and (B) were obtained by seed polymerisation using at least one butadiene polymer latex (C) with a mean particle diameter of 20 to 210 nm as seed latex and the graft rubber component III) was obtained by graft polymerisation in the presence of at least one butadiene polymer latex (C) used as seed latex for (A) and (B).
3. Polymer compositions according to claim 1, in addition at least one resin selected from an aromatic polycarbonate, aromatic polyester carbonate, polyester, polyamide or mixtures thereof.
4. Polymer compositions according to claim 1, characterised in that in the production of the graft rubber polymers the monomer feed is carried out in such a way that 55 to 90 wt.% of all the monomers to be used in the graft polymerisation are metered in during the first half of the overall time for metering in the monomers and the remaining fraction of the monomers is metered in during the second half of the overall time for metering in the monomers.
5. Polymer compositions according to claim 1 comprising characterised in that in the production of the graft rubber polymers the temperature difference between the start and end of the grafting reaction is at least 15°C.
6. Process for producing the polymer compositions according to claim 1, wherein the butadiene polymer latices (A) and (B) are obtained by seed polymerisation using at least one butadiene polymer latex (C) with a mean particle diameter of 10 to 220 nm as seed latex and the graft rubber component III) is obtained by graft polymerisation in the presence of at least one butadiene polymer latex (C) used as seed latex for (A) and (B).
7. Process for producing polymer compositions according to claim 1, characterised in that the components I), II) and optionally III) and IV) are mixed and then compounded and extruded at elevated temperature.
8. Use of the polymer composition according to claim 1 for producing moulded parts.
9. Moulded parts obtainable from polymer compositions according to claim 1.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE10008420A DE10008420A1 (en) | 2000-02-23 | 2000-02-23 | ABS-type polymer composition for production of molded parts, e.g. casings, contains at least two graft copolymers based respectively on fine and coarse polybutadiene lattices obtained by seed polymerization |
| DE10008420.6 | 2000-02-23 | ||
| PCT/EP2001/001493 WO2001062848A1 (en) | 2000-02-23 | 2001-02-12 | Polymer compositions with improved property constancy |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2400685A1 true CA2400685A1 (en) | 2001-08-30 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002400685A Abandoned CA2400685A1 (en) | 2000-02-23 | 2001-02-12 | Polymer compositions with improved property constancy |
Country Status (14)
| Country | Link |
|---|---|
| US (1) | US7060741B2 (en) |
| EP (1) | EP1268662B1 (en) |
| JP (1) | JP2003528170A (en) |
| KR (1) | KR100754696B1 (en) |
| CN (1) | CN1153811C (en) |
| AR (1) | AR027328A1 (en) |
| AU (1) | AU2001244131A1 (en) |
| BR (1) | BR0108555A (en) |
| CA (1) | CA2400685A1 (en) |
| DE (1) | DE10008420A1 (en) |
| HK (1) | HK1054047A1 (en) |
| MX (1) | MXPA02008209A (en) |
| RU (1) | RU2002125509A (en) |
| WO (1) | WO2001062848A1 (en) |
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| KR101178708B1 (en) * | 2009-08-10 | 2012-08-30 | 주식회사 엘지화학 | A rubber reinforced thermoplastic resin composition having high impact strength and good colorability |
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| EP2537895B1 (en) | 2011-06-20 | 2014-06-04 | Styrolution (Jersey) Limited | Impact modified polycarbonate compositions |
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| CN109328214B (en) | 2016-03-17 | 2021-06-22 | 英力士苯领集团股份公司 | Molding compounds for 3D printing based on SAN copolymer and polyamide blends |
| US11021602B2 (en) | 2016-04-21 | 2021-06-01 | Ineos Styrolution Group Gmbh | ABS molding composition having improved crack and chemical resistance and its use |
| KR102273553B1 (en) | 2016-04-21 | 2021-07-06 | 이네오스 스티롤루션 그룹 게엠베하 | ABS molding composition having improved cracking and chemical resistance and use thereof |
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| KR20220155613A (en) | 2016-09-27 | 2022-11-23 | 이네오스 스티롤루션 그룹 게엠베하 | Improved process for producing ASA plastics |
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-
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- 2000-02-23 DE DE10008420A patent/DE10008420A1/en not_active Withdrawn
-
2001
- 2001-01-30 AR ARP010100419A patent/AR027328A1/en unknown
- 2001-02-12 MX MXPA02008209A patent/MXPA02008209A/en active IP Right Grant
- 2001-02-12 CA CA002400685A patent/CA2400685A1/en not_active Abandoned
- 2001-02-12 WO PCT/EP2001/001493 patent/WO2001062848A1/en active Application Filing
- 2001-02-12 AU AU2001244131A patent/AU2001244131A1/en not_active Abandoned
- 2001-02-12 RU RU2002125509/04A patent/RU2002125509A/en unknown
- 2001-02-12 KR KR1020027010993A patent/KR100754696B1/en active IP Right Grant
- 2001-02-12 EP EP01916984.6A patent/EP1268662B1/en not_active Expired - Lifetime
- 2001-02-12 JP JP2001562626A patent/JP2003528170A/en active Pending
- 2001-02-12 BR BR0108555-7A patent/BR0108555A/en not_active Application Discontinuation
- 2001-02-12 US US10/204,294 patent/US7060741B2/en not_active Expired - Lifetime
- 2001-02-12 CN CNB018051898A patent/CN1153811C/en not_active Expired - Fee Related
-
2003
- 2003-09-08 HK HK03106370.4A patent/HK1054047A1/en unknown
Also Published As
| Publication number | Publication date |
|---|---|
| US20030092836A1 (en) | 2003-05-15 |
| KR20020077501A (en) | 2002-10-11 |
| CN1404505A (en) | 2003-03-19 |
| HK1054047A1 (en) | 2003-11-14 |
| JP2003528170A (en) | 2003-09-24 |
| AR027328A1 (en) | 2003-03-26 |
| EP1268662B1 (en) | 2020-11-04 |
| EP1268662A1 (en) | 2003-01-02 |
| KR100754696B1 (en) | 2007-09-03 |
| WO2001062848A1 (en) | 2001-08-30 |
| MXPA02008209A (en) | 2003-01-28 |
| DE10008420A1 (en) | 2001-08-30 |
| RU2002125509A (en) | 2004-01-10 |
| US7060741B2 (en) | 2006-06-13 |
| BR0108555A (en) | 2003-04-29 |
| CN1153811C (en) | 2004-06-16 |
| AU2001244131A1 (en) | 2001-09-03 |
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Legal Events
| Date | Code | Title | Description |
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| EEER | Examination request | ||
| FZDE | Discontinued |